BP Clair Ridge
The Bondstrand™ Weight Reduction Plan
During a project spanning 3 years, Fiber Glass Systems saved a total of 718 tonnes of weight on the Clair Ridge production platform topside modules, using Glassfiber Reinforced Epoxy (GRE) and Fiber Reinforced Polymer (FRP) composite materials and advanced engineering services.
Our composite materials provided BP with reduced future maintenance requirements, extended asset service life and enhanced safety in the harsh North Sea offshore environment near Shetland, UK, where the Clair oil-field is located.
We supported, and worked within Amec project design offices in London, directly supplying 3 kilometers of Bondstrand GRE pipe systems specified for various seawater systems, and supplied a huge portfolio of proprietary structural products in advanced fire performance phenolic FRP composite materials, all manufactured in our UK factories and shipped to the construction yard in South Korea for installation. [email protected] nov.com/fgs
Problem
Problem
The Clair Ridge project faced challenges to reduce weight, and meet low maintenance requirements. They also required custom designed and manufactured pressure vessels with strict fabrication tolerances and within a tight schedule, something that others
Solution
Solution
A total of 290 Bondstrand GRE side ported pressure vessels (8″ in diameter and 6.8m in length) were supplied for LOSAL Sea Water Reverse Osmosis (SWRO); 4 large diameter ASME X Bondstrand GRE pressure vessels (2×20” and 2×30” in diameter) were supplied for a Water Filtration Skid Package and 2,950m of Bondstrand 2400 seriesGRE pipe systems (10, 16, 20 and 24 bar) were supplied and installed for the following systems:
- Firewater
- Sewage
- Cooling Medium
- Non-Hazardous Open Drains
- Freshwater
- Hazardous Open Drains
- Seawater
- Chemical Injection
In addition to the composite pressure vessels and pipe systems installed, over 4,200 linear meters of MARRS™ offshore phenolic handrails were supplied, 8,800 sq m of I-5500 38mm phenolic FRP grating, phenolic ladders, safety gates and various FRP tertiary platforms of varying sizes and applications – All designed and manufactured by Fiber Glass Systems.
We also provided engineering support with in-house design including Finite Element Analysis (FEA) and CAESAR II analysis works. Installation support and site field service was provided at the Hyundai Heavy Industries (HHI) shipyard in South Korea.something that others were unable to provide.
Results
Results
With the use of Bondstrand composite pipe and structures, over 700 tonnes of weight was saved when compared with the use of traditional metallic materials. This in turn lowered dead weight, reducing capital costs, keeping modules within crane lift capacity and allowing for more production equipment to be installed in the HHI yard, reducing hook-up time. The use of composite materials has significantly lowered whole life costs, as it will be 40 years until the first major maintenance is required – minimizing maintenance and lifetime replacement costs. something that others were unable to provide.
| Products and Total Supply | Total Weight (T) of Metallic Equivalent | Weight Saving in Tonnes | Weight Saving % |
|---|---|---|---|
Bondstrand Pipe Systems2,950m of GRE pipe & fittings |
338,7 | 254 | 75% |
Bondstrand Structures4x Phenolic platform structures (stairwells & landings) |
60 | 40 | 67% |
| 4,200m MARRS OFFSHORE phenolic handrails | 176.4 | 117.6 | 67% |
| 8,800m² of Phenolic grating2,950m of GRE pipe & fittings | 473.4 | 307.1 | 656% |
| Total | 718.70 |
718.70
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